A method and system of forming a fire door core are provided. Hydraulic
binder and resin are supplied from raw material bins and mixed to provide
a submixture. Exfoliated vermiculite is then mixed with the submixture to
provide a mixture that is deposited into a plurality of compression
molds. Each of the filled molds are pressed in a press at a predetermined
temperature at a predetermined pressure for a predetermined period of
time sufficient to harden the mixture into a hardened slab. The hardened
slabs are then removed from the molds, impregnated with water or steam in
a water impregnation assembly and dried in a drying assembly.
